GE Drive Systems. Replacement Procedure For Motor Field Control/Power Supply Board V -

Transcription

1 GEK-ASiaJB GE Drive Systems Replacement Procedure For Motor Field Control/Power Supply Board V - S3tX111PSHA_G^ These instructions do not purport to cover al details or variations in equipment, nor to provide for every possible contingency to be met during installation, operation, and maintenance. Should further information be desired or should particular problems arise that are not covered sufficiently for the purchaser's purpose, the matter should be referred to GE Drive Systems, Salem, Virginia U.S,A. BOARD IDENTIFICATION This equipment contains a potential hazard of electrical shock or bum. Only those who are adequately trained and thoroughly familiar with the equipment and the instructions should install, operate, or maintain this equipment INTRODUCTION These instructions provide information that may be needed when replacing the drive's 531X111PSI1A_G Motor Field Control (MFC)/Power Supply Board. This information includes descriptions of the configurable hardware jumpers, switches, and potentiometers (pots). This Motor Field Control/Power Supply board pro vides the necessary -1-5 V dp, +15 V dp^ and +24 V dc power used throughout the drive: ft also contains the pulse transformer for the motor field circuitry. Three relays. RUN (Kl), MAX (K2), and FAULT (K3) are also located on this board. The latter relay provides a control interlock for operation of an externally supplied output contactor. The pan number of the board is printed on a white label that is affixed to the board* and begins with the number 53IX. This is not the number F531X that is always silkscreened directly on the board. NOTE Certain versions of cards may have a pan number suffix such as "S* or "H", instead of "G*. These boards are functionally identical to the "G' version. When ordering spare or replacement boards, be sure to use the part number on the board or on the Renewal Parts List provided with the drive. All digits are important when ordering or replacing any board. PROCEDURE FOR REPLACING BOARDS To prevent electric shock, turn off power to the board, then test to verify that no power exists in the board before touching it or any connected circuits. *Tltis number may sometimes be silkscreened directly on the board, but the part number will always begin with 53lX,

2 Motor Field Control/Power Supply Board N O T E To prevent equipment damage, do not remove boards or connections, or re-insert them, while power is applied to the drive. Treat all boards as static-sensitive. Use a ground ing strap when changing boards and always store boards in the boxes in which they were shipped. 1. Turn off power to the drive, then wait several minutes for all capacitors to discharge. Test any electrical circuits before touching them to make sure power is off. 2. Open the drive's cabinet door to access the boards, then lift and lower the first boardholder assembly to access the Motor Field Control/Power Supply Board. 3. Carefully disconnect all cables connected to the Motor Field Control/Power Supply Board as follows: For ribbon cables, place one hand on each side of the cable connector that mates with the board connector. Gently pull the cable c o n n e c t o r w i t h b o t h h a n d s. For cables with pull tabs, carefully pull the tab. For wires attached to connectors, loosen the screw located at the top of each terminal. Gently pull each wire free. For fiber-optic connectors, depress the latch on the mating cable connector. Release the six hold-down tabs and remove board. Set all configurable items on the replacement board exactly as those on the board being replaced (old board). Set all pots in the same physical position as the pots on the board being replaced. Because of upgrades, boards of different revision levels may not contain identical hardware. How ever, GE Drive Systems ensures compatibili^ of its repiacement boards. If a board revision has added or eliminated a configurable component, or re-adjustment is needed, refer to Table Install the new board verifying that all six tabs snap tightly into position. 8. The cables are labeled with the correct connector name, as marked on the board. Reconnect all cables as labeled, verifying that they are properly seated at both ends. 9. The wires are labeled with the connector name and terminal, as marked on the board. Reconnect all wires as labeled, verifying that each wire is prop erly secured in the connector. 10. On Group 5 and Group 6 Boards Only: Remove the CFU4 and CFU5 fuses from the old board and insert them into their respective slots on the new replacement board. H A R D W A R E A D J U S T M E N T S The Motor Field Control/Power Supply Board in cludes Berg-type (manually moveable) jumpers, identified by a JP nomenclature and three pots, PI thru P3. The jumpers are used for manufacturing test or customer options. Table 1 lists and provides a func tional description of the board's hardware jumpers and pots. Most jumper selections have been factory set. The test data sheets supplied with each controller (in the drive door pocket) indicate these positions. Record any jumper setting changes (that may need to be made per the notes in Table 2) on these sheets. As described previously, ensure that the jumpers and switches on the new board are placed the same as on the board being replaced. Cross reference between the board number and jumper listing per Table 2 and set any new jumpers as indicated in the notes. Set each pot in the same physical position as it was in on the board being replaced. Figure 1 shows the location of the board's jumpers, pots, test points, and fuses.

3 n 1 n «F L a u a JP1 JP2 FLO SCALE CFU6 CFU7 0' CFU8 m C F B A D J L! i l C F B Z E R O CFua CFU2 CFU5 n 1 2 FAPt. O 3 K3 CFU4 Figure 1. Motor Field ControifPower Supply Board Layout Table 1. Motor Field Control/Power Supply Board Adjustable Hardware Location M F C / P o w e r P o t Supply Board J u m p e r N u m - N o m e n - o r P o t b e r c i a t u r e PI FIELD SCALE CFB ZERO CFB ADJUST Description P1 is used to caiibrate the field current feedback using a known field current. This pot is set and sealed by the manufacturer. P2 is used to adjust offset of the current isolator circuit so that test point CFB (on Controi board) is zero. CAUTION: The drive must not be running when m a k i n g t h i s a d j u s t m e n t. P3 is used to adjust the gain of the current isolator circuit so that CFB equals the value indicated on the label inside the right side of the board compartment (in front of the Power Supply board holder). Pots P2 and P3 are interdependent and should be adjusted alternately. WARNING. ELECTRICAL SHOCK HAZARD: High voltage is present on the Power Supply Board. Remove power from the drive before handling the plug and jumpers In this procedure. 3

4 OEK-45147B Motor Field Control/Power Supply Board Table 1, Motor Field ControllPower Supply Board Adjustablee Hardware Continued Location Jumper Num- Nomeno r P o t b e r d a t u r a Description M F C / P o w e r P o t Supply Board P3 CFB ADJUST (com) P3 can be set by disconnecting the current feedback signal (DRPL) and moving jumpers JP3 and JP4 to the 2-3 position (will cause a fault 46; no concern). This applies a calibration voltage (approx. 0.1V) between pin IP and IN of DRPL P2 should be adjusted prior to moving JP3 and JP4. Adjust P3 until test point CFB on the Control board measures the value indicated on the drive calibration label. After setting P3, P2 should be rechecked. Return JP3 and JP4 to the 1*2 positions and reconnect DRPL CAUTION: If JP3 and JP4 are left in the 2-3 position. erratic operation and board failures can occur. J u m p e r J P 1 JP2 J u m p e r J P 3 JP4 JP1 and JP2 select field current feedback signal (FC) gain. Ve r s i o n G 1 M F C / P o w e r S u p p I v B o a r d J P 1 J P 2 G a i n F a c t o r F i e l d A M P R a n g e 2-3: 2-3: to 1.6 AMPS 1-2: 2-3: to 4.0 AMPS 1-2: 1-2: to 10.0 AMPS Version G2 and G5 MFC/Power Supply Board and optional Remote Field Module J P 1 J P 2 G a i n F a c t o r F i e l d A M R R a n g e 2-3: 2-3: to 6.0 AMPS 1-2: 2-3: to 12.0 AMPS 1-2: 1-2: to 24.0 AMPS JP3 and JP4 are used for calibration of the armature current feedback signal. JP3 JP4 Function 1-2: 1-2: Normal Operating Mode 2-3: 2-3: CFB calibration (See description at pot P3.) K2 coil suppression capacitor selection jumper: 1-2: Capacitor in circuit (normal). 2-3: Capacitor out of circuit. 4

5 Motor Mcid tjootrol/power Supply Board Table 2. Motor Field Control/Power Supply Board Hardware Jumper Matrix J u m p e r Group AAG1 thru APG1 531X111 PSHA^GI boards are no longer available. They have been superceded by Retrofit Kit 36B605756ADG01 that provides a G3 board, potted MOV assembly, and the necessary hardware for mounting the MOV assembly behind 3TB. Refer to procedure following this tabie for Retrofit Kit installation. AAG2 &G5 Y Y Y Y N ABG2 &G5 Y Y Y Y N ACG2 &G5 Y Y Y Y N A 0 G 2 & G 5 Y Y Y Y N AEG2 &G5 Y Y Y Y N AFG2 &G5 Y Y Y Y N AGG2 &G5 Y Y Y Y N A H G 2 & G 5 Y Y Y Y Y AJG2 &G5 Y Y Y Y Y AKG2 &G5 Y Y Y Y Y ALG2 &G5 Y Y Y Y Y AMG2 & G5 Y Y Y Y Y A N G 2 & G 5 Y Y Y Y Y APG2 &G5 Y Y Y Y Y AAG3 &G6 NA NA NA NA NA ABG3 &G6 NA NA NA NA NA A C G 3 & G 6 NA N A NA NA NA A D G 3 & G 6 NA N A NA NA NA AEG3 &G6 N A N A N A N A N A AFG3 &G6 NA NA N A NA NA A G G 3 & G 6 N A N A NA NA NA A H G 3 & G 6 NA NA N A N A NA AJG3 &G6 Y Y Y Y Y AKG3 &G6 Y Y Y Y Y ALG3 &G6 Y Y Y Y Y A M G 3 & G 6 Y Y Y Y Y A N G 3 & G 6 Y Y Y Y Y APG3 &G6 Y Y Y Y Y Y = Jumper present; set in same position on new board as was on old board. N = Jumper NOT present NA = NOT Applicable Board group differences are as follows: G1 = No Longer Available (AC line MOVs were mounted on board) G 2 = F o r u s e w i t h e x t e r n a l e x c i t e r G3 = AC line MOVs not mounted on board (parts are mounted external to board) G 4 = N o G 4 Ve r s i o n a t t h i s t i m e G5 = Same as G2 but with CFU4 and CFU5 fuses removed G6 = Same as G3 but with CFU4 and CFU5 fuses removed 5

6 56860S>S6AOG0i' RETROFIT KIT INSTAUATtON PROCEDURE 4. Remove the 3TB support post located in the center of the the 3TB mounting surface (use a short screwdriver to hold the support post screw located behind the mounting surface). To prevent electric shcclc. turn off power to the board, then test to verify that no power exists in the board before touching it or any connected circuits. Do not let drill chips fall onto/into 3TB or other parts of the drive. Remove all drill chips with a plastic nozzle vacuum cleaner prior to reapplying power to the drive. 5. Install the potted MOV assembly as follows (see Figure 2): To prevent equipment damage, do not remove boards or conneaions, or re-insert them, while power is applied to the drive. Treat all boards as static-sensitive. Use a ground ing strap when changing boards and always store boards in the boxes in which they were shipped. Turn off power to the drive, then wait several minutes for all capacitors to discharge. Test any electrical circuits before touching them to make sure power is off... Replace the 531X11 IPSHA^Gl MFC/Power Supply Board with the 531xlllPSHA_G3 board included in the retrofit kit per the 'PROCEDURE FOR REPLACING BOARDS' and 'HARDWARE ADJUSTMENTS' paragraphs of this instruction book. Remove 3TB as follows: a. Remove ribbon cables from 3TB (Place one hand on each side of the cable connector that mates with the board connector, then gently pull the cable connector with both hands.) \ a. Position the potted MOV assembly on the left side of the 3TB mounting surface and mark the four mounting hole positions. b. Drill four holes at the marked positions using a #27 drill bit. c Mount the potted MOV assembly to the 3TB mounting surface using four #8 thread forming screws. 6. Feed the red, white, and blue wire leads up to the 531X111PSHA_G3 MFCVPower Supply Board and stab the leads onto connection points MOVl, MOV2, and MOV3. (Any color lead may be connected to any of the MOV connection points). 7. Attach the piece of gasket material to the right front edge of the potted MOV assembly to provide support for 3TB. 8. Fold 3TB back up into position and secure with four (of the five) mounting screws removed in step 3a. 9. Reattach the ribbon cables removed in step 3b. b. Remove the five mounting screws from 3TB. c. Fold 3TB down and out of the way (leave other wiring in place).

7 RED. WHITE. AND BLUE WIRES TO 531X111PSHA»G3 MFC/POWER SUPPLY BOARD POINTS MOVl, M0V2, AND M0V3 POTTED M O V A S S E M B LY 3TB MOUNTING SURFACE GASKET > MATERIAL 3TB MOUNTING POSTS (QTY. 4) Figure 2. MOV Potted Assembly Mounting NOTES